The Electronic Connector Book

1. Introduction
2. Component characterization
3. Identification and selection
4. Test components
5. Terminals
6. Wire splices
7. Wiring components
8. Junction & barrier blocks
9. Terminal blocks
10. Board-in components
11. Device sockets
12. Compression components
13. Shroudless connectors
14. Rectangular connectors
15. Single-circuit connectors
16. Concentric connectors
17. Coax connectors
18. Circular connectors
19. Exterior signal connectors
20. Exterior power connectors
21. Industrial connectors
22. Adapters
23. Non-electric components
24. Design
25. Manufacture
26. Care and feeding

Chapter 1 Introduction 1
  1.1 Chapter introduction 1
  1.1.1 Tidbits 1
  1.1.2 Orientation 1
  1.2 History 1
  1.2.1 Milestones 1
  1.2.2 Example of evolution timeline 4
  1.3 FAQ 6
  1.3.1 Why so many damn connectors? 6
  1.3.2 Can you help me make a computer cable? 6
  1.3.3 How do I repair this connector? 6
  1.3.4 What is the weirdest connector you have seen? 6
  1.4 Component classification 7
  1.4.1 Manufacturer, vendor, end-user classification 7
  1.4.2 Drawing from Linnaean taxonomy 8
  1.4.3 Classes of connecting components 10
Chapter 2 Component characterization 11
  2.1 Chapter introduction 11
  2.1.1 Tidbits 11
  2.1.2 International glossary 11
  2.1.3 Orientation 17
  2.2 Terminology 17
  2.2.1 Misused or misunderstood terms 18
  2.2.2 Poorly defined and missing terms 24
  2.3 Main attributes 26
  2.3.1 Accessibility 26
  2.3.2 Structure 27
  2.3.3 Connection topology 32
  2.3.4 Permutations of main characteristics 36
  2.4 Termination and mount 39
  2.4.1 Termination introduction 39
  2.4.2 Mount introduction 41
  2.4.3 Permanent wire termination 43
  2.4.4 Removable wire termination 45
  2.4.5 Connectors with removable contacts 47
  2.4.6 Cable termination 48
  2.4.7 PCB mount and termination 50
  2.4.8 Panel mount 53
  2.4.9 Other mounts and terminations 55
  2.4.10 Termination and mount combinations 55
  2.4.11 End-to-end orientation 57
  2.5 Mating interface 60
  2.5.1 Mating general introduction 60
  2.5.2 Gender 61
  2.5.3 Contacts 66
  2.5.4 Positions, circuits, and contacts 72
  2.5.5 Shrouding 76
  2.5.6 Polarization, conforming, and keying 80
  2.5.7 Mating and unmating 86
  2.5.8 Fastening mechanisms 88
  2.6 Termination, mount, and mating 104
  2.6.1 Simple termination, mount, and mating 104
  2.6.2 Multiple termination, mount, and mating 105
  2.7 Electrical characteristics 106
  2.7.1 DC characteristics for a single circuit 107
  2.7.2 DC characteristics across circuits 109
  2.7.3 AC characteristics 111
  2.8 Physical, environmental characteristics 114
  2.8.1 Materials 114
  2.8.2 Environmental 115
  2.9 Multiple connections 116
  2.9.1 Multiple mating interface connectors 116
  2.9.2 Multiple parts connectors 118
  2.9.3 Multiple class connectors 120
  2.10 Other characteristics 120
  2.10.1 Industry-standard, proprietary, and custom 120
  2.10.2 Regulatory certifications 121
Chapter 3 Identification and selection 123
  3.1 Chapter introduction 123
  3.1.1 Tidbits 123
  3.1.2 Orientation 123
  3.2 Identification process 123
  3.2.1 Identification through navigation 124
  3.2.2 Identification by name 126
  3.2.3 Identification by pictures 127
  3.2.4 Identification by experts 130
  3.3 Selection process 131
  3.3.1 Select by attributes in this book 132
  3.3.2 Select by experts 132
  3.3.3 Select by attributes online 132
  3.4 Identification/selection by application 133
  3.4.1 Consumer products 133
  3.4.2 Solid-state lighting 136
  3.4.3 Computing devices 138
  3.4.4 Vehicles, transportation 140
  3.4.5 Premises wiring 142
  3.4.6 Other applications 145
  3.5 Selection by environment 149
  3.5.1 Demanding environments 149
  3.6 Selection by topology 152
  3.6.1 Wire-to-wire, single component 152
  3.6.2 Wire-to-wire connectors 154
  3.6.3 Cable-to-cable connectors 156
  3.6.4 Connectorless wire/cable to board 158
  3.6.5 Wire-to-board, single component 158
  3.6.6 Wire-to-board connectors 160
  3.6.7 Cable-to-board, single component 160
  3.6.8 Cable-to-board connectors 161
  3.6.9 Board-to-board topology 162
  3.6.10 Panel topologies 174
  3.7 Selection by attributes 175
  3.7.1 Selection by circuits 175
  3.7.2 Selection by structure 175
  3.7.3 Selection by wire and cable type 176
  3.7.4 Selection by ratings 177
  3.7.5 Selection by panel mount 179
  3.7.6 Selection by mating 180
  3.7.7 Selection by access 181
Chapter 4 Test components 183
  4.1 Chapter introduction 183
  4.1.1 Tidbits 183
  4.1.2 History of test components 183
  4.1.3 International glossary 184
  4.1.4 Selection, identification, and related classes 185
  4.1.5 Chapter orientation 186
  4.2 Technical notes, test components 186
  4.2.1 Insulation piercing 186
  4.3 Handheld probes 187
  4.3.1 Meter probes 187
  4.3.2 Scope probe tips 188
  4.4 Test clips 188
  4.4.1 Alligators, crocodiles, clamps 188
  4.4.2 Grabber clips 190
  4.4.3 Test fixture grabbers 190
  4.4.4 IC clips 192
Chapter 5 Terminals 193
  5.1 Chapter introduction 193
  5.1.1 Tidbits 193
  5.1.2 History of terminals 193
  5.1.3 International glossary 194
  5.1.4 Selection, identification, and related classes 195
  5.1.5 Chapter orientation 196
  5.2 Wire terminals 197
  5.2.1 Tongue crimp terminals 197
  5.2.2 Tubular compression lugs 200
  5.2.3 Wire terminals for wire-cages 201
  5.2.4 Misc. wire terminals 203
  5.3 Board terminals 204
  5.3.1 Board screw/threaded terminals 204
  5.3.2 Board pins and posts 206
  5.3.3 Board sockets 208
  5.3.4 Misc. board terminals 209
  5.4 Other mount terminals 209
  5.4.1 Loose terminals 209
  5.4.2 Solder lugs 210
  5.4.3 Magnet wire terminals 210
  5.4.4 Bus bar clips 211
  5.4.5 Foil terminals 211
Chapter 6 Wire splices 213
  6.1 Chapter introduction 213
  6.1.1 Tidbits 213
  6.1.2 History of wire splices 213
  6.1.3 International glossary 214
  6.1.4 Characteristics 215
  6.1.5 Technical notes, splices 216
  6.1.6 Selection, identification, and related classes 217
  6.1.7 Chapter orientation 218
  6.2 Catalog of splices 218
  6.2.1 Insulation displacement splices 218
  6.2.2 Crimp splices 221
  6.2.3 Solder splices 222
  6.2.4 Poke-in splices 222
  6.2.5 Lever splices 223
  6.2.6 Twist-on splices (wire nuts) 223
Chapter 7 Wiring components 225
  7.1 Chapter introduction 225
  7.1.1 Tidbits 225
  7.1.2 History of wiring components 225
  7.1.3 International glossary 227
  7.1.4 Selection, identification, and related classes 227
  7.1.5 Chapter orientation 227
  7.2 Power wiring components 228
  7.2.1 Selection, identification, and related classes 228
  7.2.2 Mechanical connectors 229
  7.2.3 Wire-cage wiring components 230
  7.2.4 Misc. power wiring components 230
  7.3 Terminal Junction Systems 231
  7.3.1 Selection, identification, and related classes 232
  7.3.2 Catalog of terminal junction components 232
  7.4 Terminal strips and boards 233
  7.4.1 Selection, identification, and related classes 233
  7.4.2 Catalog of terminals strips and boards 233
  7.5 Permanent wiring components 235
  7.5.1 Selection, identification, and related classes 235
  7.5.2 Thru-panel permanent wiring components 235
  7.5.3 On-panel permanent wiring components 237
  7.5.4 Board-to-board permanent wiring components 237
Chapter 8 Junction and barrier blocks 239
  8.1 Chapter introduction 239
  8.1.1 Tidbits 239
  8.1.2 History of junction and barrier blocks 240
  8.1.3 International glossary 240
  8.1.4 Selection, identification, and related classes 240
  8.1.5 Chapter orientation 241
  8.2 Junction blocks, nuts, blocks and bars 242
  8.2.1 Catalog of junction components 242
  8.2.2 Technical notes, junction components 244
  8.3 Barrier blocks 245
  8.3.1 Catalog of barrier blocks 245
  8.3.2 Technical notes, barrier blocks 247
Chapter 9 Terminal blocks 249
  9.1 Chapter introduction 249
  9.1.1 Tidbits 249
  9.1.2 History of terminal blocks 250
  9.1.3 International glossary 250
  9.1.4 Selection, identification, and related classes 252
  9.1.5 Chapter orientation 254
  9.2 Technical notes, terminal blocks 254
  9.2.1 Terminal blocks for specific applications 254
  9.2.2 Wire termination in wire cages 255
  9.2.3 Variable length terminal blocks 255
  9.3 Panel terminal blocks 256
  9.3.1 Tubular terminal strips, blocks 256
  9.3.2 Flush-panel-mount terminal blocks 258
  9.3.3 Feedthrough terminal blocks 259
  9.3.4 Rail mount terminal blocks 261
  9.4 PCB terminal blocks 265
  9.4.1 PCB terminal block characteristics 266
  9.5 Two-piece terminal blocks 268
  9.5.1 Two-piece terminal block characteristics 269
  9.5.2 Two-piece terminal block catalog 272
  9.6 Other pluggable terminal blocks 281
  9.6.1 Unshrouded two-piece terminal blocks 281
  9.6.2 Card edge terminal blocks 282
Chapter 10 Board-in components 283
  10.1 Chapter introduction 283
  10.1.1 Tidbits 283
  10.1.2 History of board-in components 283
  10.1.3 International glossary 283
  10.1.4 Selection, identification, and related classes 284
  10.1.5 Chapter orientation 286
  10.2 Board-in wire connectors 286
  10.2.1 Board-in wire terminals 286
  10.2.2 Board-in plugs 289
  10.2.3 Board-in PCB terminals 290
  10.2.4 Board-in PCB headers 291
  10.3 Board-in cable components 292
  10.3.1 Board-in ribbon cable connectors 292
  10.3.2 Board-in coax cable connectors 292
Chapter 11 Device sockets 295
  11.1 Chapter introduction 295
  11.1.1 Tidbits 295
  11.1.2 History of device sockets 295
  11.1.3 International glossary 296
  11.1.4 Selection, identification, and related classes 297
  11.1.5 Chapter orientation 297
  11.2 Fuse clips, blocks, and holders 298
  11.2.1 Fuse socket considerations 299
  11.2.2 Fuse socket characteristics 300
  11.2.3 Fuse socket selection and related classes 302
  11.2.4 Cartridge fuse sockets 304
  11.2.5 Automotive fuse sockets 308
  11.2.6 Other fuse sockets 310
  11.3 Cell, battery clips, holders, connectors 311
  11.3.1 Cell and battery socket considerations 311
  11.3.2 Cell/battery socket selection, related classes 313
  11.3.3 Cell and battery socket catalog 313
  11.4 Semiconductor sockets and plugs 316
  11.4.1 Semi socket selection, related classes 316
  11.4.2 Transistor sockets 316
  11.4.3 IC sockets 316
  11.4.4 DIP plugs 320
  11.5 Card edge sockets 321
  11.5.1 Card edge socket selection, related classes 322
  11.5.2 Card edge characteristics 323
  11.5.3 Card edge socket, card-side characteristics 326
  11.5.4 Card edge socket, termination characteristics 328
  11.5.5 Application-specific card edge sockets 330
  11.5.6 Card edge plugs 332
  11.5.7 Card edge males and interposers 333
  11.6 FFC/FPC sockets 334
  11.6.1 FFC/FPC socket considerations 335
  11.6.2 Poke-in FFC/FPC sockets 340
  11.6.3 Clamped FFC/FPC sockets 341
  11.6.4 Latched FFC/FPC sockets 343
  11.7 Other device sockets 343
  11.7.1 Computer card sockets 344
  11.7.2 Light bulb sockets 345
  11.7.3 Electronic component sockets 346
Chapter 12 Compression components 349
  12.1 Chapter introduction 349
  12.1.1 Tidbits 349
  12.1.2 History of compression components 350
  12.1.3 International glossary 350
  12.1.4 Selection, identification, and related classes 350
  12.1.5 Chapter orientation 350
  12.2 Catalog of compression components 351
  12.2.1 Spring-loaded components 351
  12.2.2 EMI shielding products 356
  12.2.3 Direct wire-to-board plugs 357
  12.2.4 Direct board-to-board components 359
  12.2.5 LED strip components 360
Chapter 13 Unshrouded connectors 361
  13.1 Chapter introduction 361
  13.1.1 Tidbits 361
  13.1.2 History of unshrouded connectors 361
  13.1.3 International glossary 362
  13.1.4 Selection, identification, and related classes 362
  13.1.5 Chapter orientation 363
  13.2 Technical notes, unshrouded connectors 363
  13.2.1 Contrast with unshrouded connectors 363
  13.2.2 Unshrouded connector characteristics 363
  13.2.3 Applications of unshrouded connectors 365
  13.3 Catalog of unshrouded connectors 366
  13.3.1 Unshrouded PCB headers 366
  13.3.2 Unshrouded plugs 369
  13.3.3 Programming jumpers/shunts 370
Chapter 14 Rectangular connectors 371
  14.1 Chapter introduction 371
  14.1.1 Tidbits 371
  14.1.2 History of rectangular connectors 371
  14.1.3 International glossary 372
  14.1.4 Selection, identification, and related classes 373
  14.1.5 Chapter orientation 374
  14.2 Technical notes, rectangular connectors 375
  14.2.1 Fastening of rectangular connectors 375
  14.2.2 Contact arrangement, numbering 376
  14.2.3 Keying of rectangular connectors 379
  14.2.4 Contact extraction 380
  14.3 Board-to-board connectors 380
  14.3.1 Board-to-board connectors topologies 380
  14.3.2 Technical notes, board-to-board connectors 385
  14.3.3 Small genderless board-to-board connectors 386
  14.3.4 Small gendered board-to-board connectors 390
  14.3.5 Array board-to-board connectors 391
  14.3.6 High-power board-to-board connectors 396
  14.3.7 Large, unshrouded board-to-board connectors 400
  14.4 Wire-to-board connectors 401
  14.4.1 Single-wall connectors 401
  14.4.2 Low profile wire-to-board connectors 404
  14.4.3 Standard profile wire-to-board connectors 408
  14.4.4 Sidelined wire-to-board connectors 409
  14.4.5 LVDS connectors 410
  14.4.6 Unshrouded wire-to-board connectors 411
  14.5 Wire-to-wire connectors 413
  14.6 General-purpose connectors 413
  14.6.1 Prismatic connectors 414
  14.6.2 Pin-and-socket connectors 419
  14.6.3 Partitioned shroud connectors 421
  14.6.4 Misc. industry-standard rectangular conn. 428
  14.6.5 Proprietary rectangular connectors 430
  14.7 Application-specific connectors 431
  14.7.1 Appliance connectors 432
  14.7.2 Automotive connectors 433
  14.7.3 RC model connectors 442
  14.7.4 Drawer connectors 443
  14.7.5 Hot-pluggable connectors 446
  14.7.6 Misc. application-specific connectors 449
Chapter 15 Single-circuit connectors 453
  15.1 Chapter introduction 453
  15.1.1 Tidbits 453
  15.1.2 History of single-circuit connectors 453
  15.1.3 International glossary 454
  15.1.4 Selection, identification, and related classes 455
  15.1.5 Chapter orientation 456
  15.2 Disconnects 457
  15.2.1 Tab disconnects 457
  15.2.2 Other disconnects 460
  15.3 Exposed-pin connectors 460
  15.3.1 Signal exposed-pin connectors 461
  15.3.2 High-current exposed-pin connectors 463
  15.4 Unipole connectors 464
  15.4.1 Round unipole connectors 465
  15.4.2 Rectangular unipole connectors 469
Chapter 16 Concentric connectors 471
  16.1 Chapter introduction 471
  16.1.1 Tidbits 472
  16.1.2 History of concentric connectors 472
  16.1.3 International glossary 473
  16.1.4 Selection, identification, and related classes 474
  16.1.5 Chapter orientation 474
  16.2 Catalog of concentric connectors 474
  16.2.1 Phone connectors 474
  16.2.2 Coaxial barrel power connectors 477
  16.2.3 Other concentric connectors 480
Chapter 17 Coax connectors 483
  17.1 Chapter introduction 483
  17.1.1 Tidbits 484
  17.1.2 History of coax/RF connectors 484
  17.1.3 International glossary 484
  17.1.4 Selection, identification, and related classes 484
  17.1.5 Chapter orientation 486
  17.2 Technical notes, coax connectors 486
  17.2.1 Coaxial connector electrical characteristics 486
  17.2.2 Coaxial connector mechanical characteristics 490
  17.2.3 Coaxial connector mount and termination 493
  17.3 Catalog of coax/RF connectors 497
  17.3.1 Interior RF connectors 497
  17.3.2 Microwave connectors 499
  17.3.3 Standard exterior RF connectors 505
  17.3.4 Non-standard exterior RF connectors 514
  17.3.5 Non-RF coaxial connectors 517
  17.4 Coaxial ancillary components 519
  17.4.1 Coax couplers, adapters, and splitters 520
  17.4.2 Coax terminators and attenuators 521
  17.4.3 Coax accessories 522
Chapter 18 Circular connectors 523
  18.1 Chapter introduction 523
  18.1.1 Tidbits 524
  18.1.2 History of circular connectors 524
  18.1.3 International glossary 525
  18.1.4 Selection, identification, and related classes 525
  18.1.5 Chapter orientation 527
  18.2 Technical notes, circular connectors 527
  18.2.1 Circular connector characteristics and usage 528
  18.3 Industry-standard circular connectors 533
  18.3.1 XLR, Mini-XLR circular connectors 533
  18.3.2 DIN-type circular connectors 534
  18.3.3 MIL-spec circular connectors 538
  18.3.4 IEC-type circular connectors 541
  18.3.5 Classic metal circular connectors 549
  18.4 Semi-standard circular connectors 552
  18.4.1 Slim circular connectors 552
  18.4.2 Misc. semi-standard circular connectors 555
  18.5 Application-specific connectors 559
  18.5.1 Automotive circular connectors 559
  18.5.2 E-bike connectors 561
  18.5.3 Other transportation circular connectors 564
  18.5.4 Lighting circular connectors 565
  18.5.5 Circular connectors for extreme environments 567
  18.5.6 Communications circular connectors 570
  18.6 Proprietary circular connectors 570
  18.7 Irregular circular connectors 572
  18.7.1 Round connectors with sub-connectors 572
  18.7.2 Irregular shroud circular connectors 573
  18.7.3 Genderless circular connectors 574
Chapter 19 Exterior signal connectors 577
  19.1 Chapter introduction 577
  19.1.1 Tidbits 577
  19.1.2 History of exterior signal connectors 577
  19.1.3 International glossary 579
  19.1.4 Selection, identification, and related classes 579
  19.1.5 Chapter orientation 580
  19.2 General-purpose signal connectors 580
  19.2.1 D-shell connectors 580
  19.2.2 Telephone and modular connectors 586
  19.3 Data I/O connectors 588
  19.3.1 USB connectors 588
  19.3.2 Other consumer data I/O connectors 592
  19.3.3 Video I/O connectors 594
Chapter 20 Exterior power connectors 597
  20.1 Chapter introduction 597
  20.1.1 Tidbits 597
  20.1.2 History of exterior power connectors 597
  20.1.3 International glossary 600
  20.1.4 Selection, identification, and related classes 600
  20.1.5 Chapter orientation 601
  20.2 Technical notes, exterior power conn. 601
  20.2.1 Power connector terminology 601
  20.2.2 Power connector termination 603
  20.3 AC power connectors 604
  20.3.1 Country-specific AC power connectors 604
  20.3.2 Appliance coupler 616
  20.3.3 NEMA twist-lock connectors 619
  20.3.4 Pin-and-sleeve AC power connectors 621
  20.3.5 Industry-specific AC power connectors 623
  20.3.6 Weird AC connectors 625
  20.4 DC power connectors 626
  20.4.1 DC couplers 626
  20.4.2 Electric vehicle DC connectors 627
  20.4.3 Vintage exterior power connectors 629
Chapter 21 Industrial connectors 631
  21.1 Chapter introduction 631
Chapter 22 Adapters 633
  22.1 Adapters catalog 633
Chapter 23 Non-electric components 635
  23.1 Chapter introduction 635
  23.2 Non-electric connectors 635
  23.2.1 Fiber-optic connectors 635
  23.2.2 Radio wave connectors 636
  23.3 Connector accessories 637
  23.3.1 Configurable frames 638
  23.3.2 Cable accessories 638
Chapter 24 Product design 641
  24.1 Chapter introduction 641
  24.1.1 Chapter orientation 641
  24.2 Component testing 641
  24.2.1 Electrical testing 641
  24.2.2 Mechanical testing 642
  24.3 Electrical design 643
  24.3.1 Symbols and labels 643
  24.4 PCB design 645
  24.4.1 PCB design for connectors 645
  24.4.2 Card edge design 646
  24.5 Design for manufacturability 649
Chapter 25 Manufacturing 651
  25.1 Chapter introduction 651
  25.1.1 Orientation 651
  25.2 Wire termination 651
  25.2.1 Wire prep for terminal blocks 651
  25.2.2 Wire soldering 652
  25.2.3 Wire crimping 652
  25.3 Cable termination 656
  25.3.1 Control cable termination 656
  25.3.2 Ribbon cable mass termination 657
  25.3.3 Shielded cable termination 658
  25.3.4 Zip cord termination 658
  25.3.5 Coax cable termination 659
  25.4 PCB and panel mount 661
  25.4.1 PCB-mount 661
  25.4.2 Panel mounting 662
  25.5 Testing 663
  25.5.1 Factory testing 663
Chapter 26 Care and feeding 665
  26.1 Chapter introduction 665
  26.2 Usage 665
  26.2.1 Coax connectors 665
  26.2.2 Lubrication 667
  26.3 Repair 667
  26.3.1 Connector repair 667
  26.3.2 Cable assembly repair 669
  26.4 Modification 669
  26.4.1 Wrong connector 669
  26.4.2 Cable modification 670
  A Appendix 671
  A.1.1 Tidbits 671
  A.2 Behind the scenes 671
  A.2.1 Classification challenges 671
  A.2.2 Naming challenges 673
  A.3 Conductors for termination 674
  A.3.1 Wire 675
  A.3.2 Cable 676
  A.3.3 Coaxial cable 681
  A.3.4 Boards 684
  A.3.5 Other conductors 686
  A.4 Connectorless connections 687
  A.4.1 Connectorless wire-to- wire connections 687
  A.4.2 Connectorless cable-to-board connections 687
  A.4.3 Connectorless board-to-board connections 689
  A.5 Custom connectors 689
  A.6 Resources 690
  A.6.1 Books 690
  A.6.2 Online resources 690
  A.6.3 Market reports 691
  A.6.4 Trade shows 691
  A.6.5 Manufacturers 691
  A.6.6 Associations and consortia 691
  A.6.7 Services 692